ASTM A105 Forge Carbon Steel Material Specification

ASTM A105 is the most commonly used carbon steel material grade that is used to manufacture forge piping components such as flange and forged
fittings of small diameter piping. This carbon steel material grade is used for ambient- and higher-temperature service in pressure systems.

Some of the components that are made by ASTM A105 are listed below.

1. Flanges 4. Pressure vessel forge components such as a self-reinforced

2. Valve Body nozzle, nozzle neck, etc.
3. Forged Fittings such as Elbow, Tee, Coupling, etc. 5. As designed by Purchasers
However, there is a limitation on the use of this standard. The weight of the forging made by A105 material should not exceed 4540 Kgs. Forging
heavier than 4540 Kgs is made by using ASTM A266

ASTM A105 Material Properties

Only fully killed carbon steel material is used for forging. This material can be in the shape of a bar or in the shape of an ingot to meet various
forging requirements. See the image below.

This bar is then cut into the required length to do the forging of a flange. See the video below to understand the flange forging process. You can see
the closed die flange manufacturing process.

In the image below, you can see various ASTM A105 products such as a flange, fittings, nozzle neck, and self-reinforced branches that are used in
industries such as oil and gas, petrochemical, power plant, etc.
Heat Treatment is a must for all the products manufactured with ASTM A105 except the following.

1. Flange Class 150 and Class 300

2. Piping component NPS 4 and below with pressure class 300 or less
Following Hear Treatment method, you can use.

• Annealing – In Annealing, the material shall be uniformly reheated to a temperature above the transformation range and, after holding for a
sufficient time at this temperature, cooled slowly to a temperature below the transformation range.

• Normalizing – In Normalizing, the material is uniformly reheated to a temperature above the transformation range and subsequently cooled
in the air at room temperature.

• Normalizing and tempering

• Quenching and tempering – In this method, the material is first fully austenitized and then quenched immediately in a suitable liquid
medium. The quenched fittings were again reheated to a minimum temperature of 590°C or 1100°F and then cooled in still air.

Chemical Composition of ASTM A105 Materials

Refer table below for the chemical composition.

Material Percentage %

Carbon 0.35 max

Manganese 0.60–1.05

Phosphorus 0.035 max

Sulphur 0.040 max

Silicon 0.10–0.35

Copper 0.40 max

Nickel 0.40 max

Chromium 0.30 max

Molybdenum 0.12 max

Vanadium 0.08 max

Columbium 0.02 max

The sum of copper, nickel, chromium, molybdenum and vanadium shall not exceed 1.00 %.

The sum of chromium and molybdenum shall not exceed 0.32 %.

For each reduction of 0.01 % below the specified carbon maximum (0.35 %), an increase of 0.06 % manganese above the specified
maximum (1.05 %) will be permitted up to a maximum of 1.35 %.

Mechanical Properties of ASTM A105 Materials

To confirm the strength and ductility of the material, tensile tests and hardness tests are performed on the specimen. This specimen is cut out from the sample
that is heat-treated along with the final product. In the video below, you can see how the tensile test is performed on the test specimen.
Acceptable values of mechanical testing results are given in the table below.

Tensile Strength min. Yield Strength min. Elongation min. Reduction of Area, min. Hardness

MPa ksi MPa ksi % % HB

485 70 250 36 22 30 137-187

Number of Sample Testing requirements

One tension test shall be made for each heat of as-forged components.
If the entire batch is heat-treated in a single lot, one test specimen per heat number. Otherwise, each batch of heat treatment shall have one
sample of test specimens per heat number.
Material Heat Number in MTC
A heat number, also known as a cast number, plays a significant role in various industries, particularly in sectors like Oil and Gas. A material heat number is a
unique identification number assigned to each batch or lot of material during the manufacturing process of raw steel such as billets and ingots.
It is crucial for traceability, quality control, and material identification purposes throughout the lifecycle of the steel product such as pipes, fittings, flanges, and
steel plates.
Table of Contents

• Importance of Material Heat Number • Enhancing Product Integrity

• Traceability and Quality Control Using Material Test Report • Lifecycle Tracking
• Verification and Inspections
Importance of Material Heat Number

The material heat number is typically stamped or marked directly on the material itself. It consists of alphanumeric characters that make it unique to each batch
or lot of material. This number may also contain additional information, such as the date of production or the supplier’s code.

With the use of this code, you can trace back the material to its origin.

Traceability and Quality Control Using Material Test Report

• By referencing the material heat number from MTC / MTR, manufacturers, suppliers, and customers can gain access to detailed records or certificates.
These documents provide valuable information about the material’s chemical composition, heat treatment records, mechanical properties, and
production history.
• This level of traceability is essential for ensuring the material’s quality and suitability for its intended application.
Verification and Inspections

Having the material heat number allows stakeholders to verify the material’s authenticity and quality. It provides a means to cross-reference the material’s
properties with the specifications required for a particular project or product. Manufacturers and customers can perform inspections based on the material’s
heat number to ensure it meets the necessary material standards.

Enhancing Product Integrity

By maintaining a comprehensive system of material heat numbers and associated records, industries can enhance the overall integrity of their products.
Knowing the exact composition and history of the materials used allows for better control over the manufacturing process and minimizes the risk of using
substandard or incorrect materials.

Lifecycle Tracking

The material heat number enables the tracking of materials throughout their entire lifecycle. From the initial manufacturing stage to the end of the product’s life,
the heat number serves as an essential reference for any issues, maintenance, or replacements that may arise.

In conclusion, the heat number, or cast number, is a vital element in Material Certificates (MTCs) and quality assurance processes.

Its unique identification feature ensures traceability and facilitates easy access to crucial information about the material. By utilizing this identification system,
industries can maintain high-quality standards, conduct effective inspections, and enhance the overall reliability of their products
Importance of Material Traceability During the Fabrication
Material traceability is extremely important during fabrication of piping and equipment that will be used in Oil and Gas facilities. In this article, you will learn
about the importance of material traceability during fabrication.
You will learn what material traceability is, why it is important, and how traceability is maintained throughout the fabrication.

What is Material Traceability?

Material traceability refers to the process of tracing back all the bulk materials used in fabrication, such as pipes, fittings, flanges, and plates, to their origin at any
given time. It involves establishing a system that can trace each material along with its original material test certificate. This system allows you to identify the
supplier, the specific material, and its associated information, like the heat number, whenever required.

Why is Material Traceability Important?

Material traceability plays a crucial role in ensuring the integrity and reliability of fabricated piping and equipment, especially in industries like Oil and Gas. Let’s
understand why it holds such significance.

Identification of Defective Materials

In the fabrication process, there may be instances where certain materials turn out to be faulty or fail to meet the required standards. Identifying such defective
materials becomes essential to avoid potential failures during operation.
In one of the projects that I worked on; we got a few 100 flanges from one supplier. After a few months, we got a letter from the supplier that there was an issue
with one particular lot. These flanges were failing in the impact test.
Now that most of the fabrication work was already completed, how will you identify those flanges with problems?

Material traceability enables you to trace and replace these faulty materials promptly, ensuring the safety and efficiency of the process plant.
A similar issue may arise during the operation. Let’s say some materials fail within a short operation time due to metallurgical or heat treatment-related issues. To
avoid future failure at other places, you must trace all such defective materials and replace them as soon as possible.
In all such situations, you must replace faulty materials to safeguard your process plant. With the help of a material traceability system in your fabrication, you
can easily trace and replace such materials.

Compliance with Quality Standards

Material traceability is closely linked to quality assurance and compliance. By maintaining a traceability system, you can demonstrate adherence to quality
standards, regulatory requirements, and industry-specific certifications. This not only enhances your credibility but also provides assurance to stakeholders
regarding the quality of the fabricated products.

Efficient Maintenance and Repair

During the operation of a process plant, maintenance and repair activities are inevitable. Material traceability simplifies these tasks by enabling easy
identification and replacement of specific components or materials. It saves time and resources that would otherwise be spent on extensive inspections or trial-
and-error approaches.

How to Maintain Material Traceability?

Now that we understand the significance of material traceability, let’s learn how it is maintained during fabrication.

Inward Material Inspection

The process begins with an inward material inspection, which verifies the quality and conformity of incoming materials. This inspection ensures that the
materials meet the required specifications before they are used in the fabrication. You can learn more about this process in my earlier video given below.
Marking and Material Identification

Before using materials like pipes and plates for fabrication, they are marked with part numbers and Material IDs. These markings serve as a unique identifier for
each component and help maintain traceability. An inspection engineer checks the marking and puts a unique stamp on each part, ensuring their traceability
even if the original manufacturer’s marking is no longer visible. Markings can be made using a hard punch or a paint marker, depending on the thickness of the
material.

Fit-up Inspection

During the fit-up stage, components like fittings, flanges, and pipes are assembled for welding. Each component is marked individually, and their markings are
recorded during a fit-up inspection. The heat numbers of these components are also documented. This information is crucial for material traceability and gets
transferred to the line history steel when prepared.

During Fabrication
Now, let’s learn how to ensure proper traceability in the next stages of fabrication. Here, in the image, you can see a pipe spool fitup. There are three
components and two welding joints in this spool. A flange, pipe, and elbow.

Now we have three components that are going to weld together. Once these are welded, they are a permanent part of the project. So, if we establish tracking at
this stage, it will remain traceable forever.

Part No. Part Description

Part-1 – 101 Flange – 6”, Class 150, A105 Gr.B Sch80

Part-2 – 102 Pipe – 6” Sch 80, A106 Gr.B

Part-3 – 103 90° Elbow – 6” Sch 80 – A234 WPB

Below, you can see the sample fitup inspection report. This report records things like drawings, lines, spool, joint number, and the joint’s dimension.

Now, these two columns are of interest and critical for material traceability. In our example, joint number two is elbow to pipe. So, the first column records base
material part one, a 90-degree elbow, and the second part, a pipe. Similarly, the first joint is a pipe to flange. You have to record the material details of both
components. When the line history steel is prepared, these material details will get transferred into that. So this is how material traceability is maintained in the
piping.
Metal Tagging and Spool Numbering
To ensure traceability throughout the fabrication and installation process, it is common practice to put metal tags on spools or write the spool numbers inside the
pipes using a paint marker. This allows for easy identification and tracking of specific spools or welded materials, even after painting and during field installation.

Conclusion

Material traceability is of utmost importance during the fabrication of piping and equipment in industries like Oil and Gas. It ensures the
identification of defective materials and compliance with quality standards and facilitates efficient maintenance and repair activities.
By establishing a robust material traceability system, you can enhance the reliability and safety of your process plant.
What is Inward Material Inspection?
Inward material Inspection is an essential part of the fabrication process for piping and equipment used in Oil and Gas facilities. It serves as
a quality control measure to ensure that the materials used in the process plant meet the required specifications and standards.

What is Inward Material Inspection?

Inward Material Inspection is the process of inspecting all raw materials, such as pipes, plates, flanges, fittings, and any other materials at
the site store or warehouse before being issued for fabrication. It is a routine practice and integral to the project quality management
system.

The inspection department confirms that the correct material has been received in the ordered quantity and with the proper documentation.
In other words, it is like checking the delivery of your online order before using the product.

Please note that inward material inspection is not a product quality inspection but a product verification inspection. It is a two-part process,
where you check the documentation in the first part and physically verify the materials in the second part.

Related Questions

Q-What is an inward inspection? / What is incoming material inspection? / What is inward quality?

A- Inward inspection, also known as incoming inspection or receiving inspection or inward quality checks, is a quality control process that is
carried out upon receipt of materials or components from suppliers or vendors before using at the site.

How to Do Inward Material Inspection?

Inward Material Inspection consists of two parts:

Documentation Verification
Before conducting the physical inspection of materials, it is crucial to ensure that all the required documents are in place. These documents
provide vital information about the materials and their compliance with relevant standards. Some of the key documents to check include:
1. Inspection Release Note (IRN): This note confirms that the materials have undergone inspection and are approved for use.
2. Packing List: It provides a detailed list of the materials contained in the shipment.
3. Inspection and Test Reports: These reports, such as Material Test Certificates (MTC) and dimension reports, provide information
about the material’s properties and test results.
4. Compliance Certificate: This certificate indicates that the materials meet the required compliance standards.
5. Manufacturing Record Book (MRB): It contains a comprehensive record of the materials’ manufacturing processes.
6. Installation Manual: This manual guides the proper installation of specific equipment or components.
It’s worth mentioning that not all documents may be applicable to every situation. Some documents, such as MRB and the Installation
Manual, are only required for equipment and tag items, not for bulk materials such as piping, electrical, and instrument.

Physical Material Verification

The physical verification of materials is conducted in the field to establish their identification before they are issued for fabrication. During
this stage, several aspects need to be assessed:
1. Overall Material Quality: Check for any signs of rusting, paint damage, or other quality issues.
2. Packaging Condition: Ensure that the packaging is intact and suitable for protecting the materials during transportation.
3. Quantity Received: Verify that the received quantity matches the ordered quantity.
4. Transit Damage: Inspect for any dents, breakages, or other damages that may have occurred during transit.
It is essential to record all observations and findings during the physical verification process. Positive Material Identification (PMI) is carried
out for alloy and stainless-steel materials to ensure their composition meets the required specifications. As indicated in the Material Test
Certificate (MTC), the material’s marking plays a critical role in the inspection process.
Once all the requirements are met, an Inward Material Inspection Report (IMIR) is prepared, and the materials are marked with a unique
identification (ID) to ensure traceability throughout the fabrication process. This unique ID differs from the original marking that comes with
the product. It serves as a shorter, easily maintainable marking during fabrication and installation.

How to Prepare Inward Material Inspection Report (IMIR)?

The Inward Material Inspection Report is a comprehensive record of the inspection findings and the first step for the material traceability
system. It includes the following information:

1. Report Number: A unique identifier for the inspection report.

2. Purchase Order Number: The number associated with the purchase order for the materials.

3. Inspection Date: The date when the inspection was conducted.

4. Material Location: The designated location of the materials.

5. Material Type: The type of material being inspected (e.g., pipe, elbow, tee, valve).

6. Description: Technical details about the product, including applicable material standards, specifications, size, thickness, schedule
number, and material grade.

7. Supplier Name: The name of the manufacturer or supplier from whom the materials were procured.

8. Commodity Codes: Short codes used to identify specific material types in the drawings, aiding proper material identification.

9. PO Item Number: The serial number of the material in the purchase order.

10. Quantity Unit: The unit of quantity used for the specific type of material (e.g., meters, numbers, kilograms).

11. Tags: For assembled items such as valves, filters, or instrument items, tags are listed in the IMIR report.

12. MTC and Heat Numbers: The Material Test Certificate (MTC) and Heat Numbers are recorded to confirm appropriate testing and
quality standards. Heat Numbers provide unique identification for a specific batch or lot of material during its manufacturing
process.

13. Unique ID: A marking assigned to each item to ensure traceability throughout the fabrication and installation processes. It is a shorter
version that can be easily maintained during the fabrication. Each company has a different method of giving ID to the material.

14. Remarks: Here, you can add any observation about the material.

The IMIR report helps maintain a clear record of the inspection process and serves as a reference for future use.

Usually, this marking transfer is done during the cutout marking inspection.

Conclusion

Inward Material Inspection is a crucial step in the fabrication process of piping and equipment used in Oil and Gas facilities. By verifying the
received materials against documentation and conducting physical inspections, it ensures the adherence to required specifications and
standards. Preparing an Inward Material Inspection Report (IMIR) provides a detailed record of the inspection findings and ensures
traceability throughout the fabrication process.

Maintaining quality and traceability throughout the fabrication process is vital to ensure the integrity and safety of oil and gas facilities. By
conducting thorough inward material inspections, companies can mitigate risks and ensure the successful completion of their projects.
4 Types of Inspection Certificates (2.1, 2.2, 3.1, and 3.2) as per EN 10204

What is EN 10204, and why is it so Important?

When it comes to ensuring the quality and compliance of metallic products used in Oil and Gas industries, an inspection of materials plays a vital
role.
Depending on the purchase order requirements, these certificates provide crucial information about the inspection and testing processes that steel
product has undergone.
The most recognized standard for types of inspection certificates is European standard EN 10204. It is a specification for “Metallic products – Types
of inspection documents.” and specifies the requirements for inspection documents.
What are the Most Commonly Used Types of Certificates?

There are four different types of inspection certificates.

1. Type 2.1 – Certificate of Declaration 3. Type 3.1 – Specific Inspection

2. Type 2.2 – Non-Specific Inspection 4. Type 3.2 – Specific Inspection by Third Party

What is an EN 10204 2.1 Mill Test Certificate?

The first type is the Type 2.1 certificate. This certificate serves as a statement of compliance with the order. The manufacturer declares that the products
supplied the requirements but does not provide any test results. It is basically a declaration from the manufacturer or supplier that the products supplied
have been produced according to the agreed-upon specifications, and you can trust us.

What is an EN 10204 2.2 Material Certificate Type?

Moving on to the next, we have the Type 2.2 certificate type. It also includes a statement of compliance issued by the manufacturer with the order, but it
goes a step further.

It provides test results based on non-specific inspections carried out by the manufacturer. These tests are typically basic and do not cover all aspects of
the product’s conformity. But What is a non-specific inspection? Well, Non-specific inspection refers to an inspection process conducted by a
manufacturer based on their own established procedures.

The purpose of this inspection is to determine whether products, which are defined by a specific product specification and manufactured using the same
process, meet the requirements of the purchase order or not.

In simpler words, the manufacturer examines the products they have produced to ensure that they conform to the specifications outlined in the purchase
order. This inspection is carried out using the manufacturer’s internal procedures rather than relying on any external or standardized criteria.

What is an EN 10204 3.1 Material Certificate?

Now, let’s talk about the Type 3.1 certificate. This is a more comprehensive type of inspection certificate that ensures a higher level of quality assurance.

It is issued by the manufacturer’s authorized inspection representative, who is independent of the manufacturing department and confirms that the
products have been tested according to specific standards.
It means that all the tests and inspections are carried out and witnessed by a separate Inspection department and not by the production department.

The results of these tests must comply with the requirements stated in the material standards. The EN 10204 Type 3.1 inspection certificate may also
include additional test results, providing more detailed information about the product’s conformity.

What is an EN 10204 3.2 Material Certificate?

Finally, we have the Type 3.2 inspection certificate, which offers the highest level of assurance. This certificate involves independent verification by a
third-party inspection authority. This third party may be the purchaser’s authorized person or by inspector of independent inspection agencies.

To certify the material with a Type 3.2 certificate, in addition to the manufacturer’s inspection department, the third party performs and
witnesses its own inspections and tests.

The Type 3.2 certificate includes test reports and statements of compliance from both the manufacturer and the third-party authority. This
independent verification adds an extra layer of confidence in the product’s quality and conformity.

Please note that in the case of 3.1 and 3.2 material test certificates, inspection and testing are carried out based on the specific inspection requirements
stated in the material standard, such as ASME, ASTM, or API, and not the manufacturer’s own standard.

Summary

These certificates provide crucial information about the inspection and testing processes that a product has undergone. It also ensures transparency and
traceability in various industries.

Manufacturers and customers can choose the appropriate type of certificate based on their specific requirements to establish trust and meet regulatory
standards.
Difference Between 2.2 and 3.1 Material Certificates

In this blog, you will learn about What is the difference between 2.2 and 3.1 Material test certificates? The main difference between the 2.2 and 3.1
material certificates lies in the level of verification and confidence they offer. Material Test Certificate is a key document for product quality
assurance. Knowing the difference between them is important.

Type 2.2 MTC Type 3.1 MTC

Declaration Certificate Inspection by Independent Inspection department of Manufacturer’s

Testing as per Manufacturer’s internal testing criteria Testing as per Standards testing criteria

Trust level – Low Trust level – Medium

Non – Specific Inspection Specific Inspection

What is Type 2.2 Material Certificate?

The Type 2.2 certificate is a declaration certificate that includes some test results. The main difference is that these tests are conducted based on
the manufacturer’s internal testing criteria.

This means that the material procured with this test certificate is a general statement of compliance and indicates that the material meets the basic
requirements of the relevant standard. It may include details such as the material’s chemical composition, mechanical properties, and sometimes
dimensions.

However, these test results may not be in line with internationally recognized standards but are based on the manufacturers or supplier’s own
internal testing and quality control procedures. This is also known as non-specific inspection.

What is Type 3.1 Material Certificate?

On the other hand, the 3.1 certificate is more comprehensive and stringent compared to the 2.2 certificate. It ensures a higher level of
quality control and verification processes.

The 3.1 material test certificate, issued by the manufacturer or supplier, states that the material has been tested in accordance with specific
standards and confirms the chemical composition, mechanical properties, and other essential parameters.

This verification is conducted by a manufacturer’s authorized inspection agency that is independent from the manufacturing department.
It’s important to note that this independent inspection agency is not the same as the independent third-party inspection agency that is
external to the manufacturer.

However, the Type 3.1 MTC provides a higher level of confidence and assurance regarding the material’s quality, as it involves material
verification and testing in line with recognized material standards. This is also known as specific inspection.

In summary, the main difference between the 2.2 and 3.1 material certificates lies in the level of verification and confidence they offer. The
2.2 certificate is based on the manufacturer’s internal testing, while the 3.1 certificate involves standard verification.
What is the Difference Between 3.1 and 3.2 MTC?

What is a Material Test Certificate (MTC)?

A material test certificate MTC, also known as a mill certificate, is an official document provided by the manufacturer or supplier to the
purchaser that validates the properties and characteristics of the material being used.

Here, in the table, you can see when Type 3.1 MTC is being issued and when Tyep3.2.

Type 3.1 MTC Type 3.2 MTC

Inspection by Manufacturer’s Inspection Team Inspection by Independent Inspection Agency

Trust level – Medium Trust level – High

Type 3.1 Material Test Certificate

The 3.1 material test certificate is issued by the manufacturer and states that the material has been tested in accordance with specific
standards. It confirms the chemical composition, mechanical properties, and other essential parameters.

However, the inspection and testing process are carried out by the manufacturer’s Inspection department, which is not part of the
manufacturing department. So, here trust level is not that high as everything is in-house business.

Type 3.2 Material Test Certificate

For critical applications, we have to be 100% sure about our material. This issue is solved by the Type 3.2 certificate.

The 3.2 material test certificate takes the level of assurance to a higher degree. This certificate involves the intervention of an independent
third-party inspection agency. This third party may be the purchaser’s authorized person or independent inspection agencies. They conduct
additional checks, verifications, and tests to ensure that the material meets the specified requirements.

The third-party inspector reviews the manufacturing process, performs random sampling, and may even witness specific tests. This
comprehensive evaluation guarantees a higher level of confidence in the quality and integrity of the material being certified.

I hope you found this video helpful in understanding the difference between the 3.1 and 3.2 material test certificates. If you enjoyed this
video, make sure to hit the like button and subscribe to my channel for more informative videos like this one.
How to Review Material Test Certificates (MTR) During Material Inspection?

The Review of Material Test Certificates which is also known as Material Test Report (MTR) is crucial to ensure the quality of materials used in oil and gas
fabrication. All raw materials used in the Oil and Gas industry, such as pipes, fittings, flanges, and plates, must have a valid Material Test Certificate (MTC)
provided by the manufacturer.

The inspection engineer is responsible for confirming that the material’s test certificate aligns with the requirements specified in the applicable material
standards, specifications, and purchase order.

In this article, you’ll learn how to read and review the Mill Test Report during the shop and inward material inspection.

Reviewing the MTC involves several steps, including material identification and traceability check, chemical composition analysis, assessment of mechanical
properties, evaluation of non-destructive testing (NDT) results, review of heat treatment information, examination of dimensions and tolerances, and
consideration of non-technical information such as the manufacturer’s name and address, purchase order number, and date.

For this article, I’ve chosen the Seamless Pipe Material Test Certificate as an example. From now on, I’ll refer to the Material Test Certificate as MTC, MTR, or TC
for simplicity. Here’s a sample MTC for a seamless pipe.

I’ve numbered each step to make it easier to follow. You can download the full mill test certificate from this link – Sample Material Test Certificate of Seamless
Pipe.

Review Material Test Report and Type of Certificate

Step 1 – Type of Material Certificate

The first thing you’ll notice on the certificate is the type of inspection certificate. In this case, you can see that this TC is issued in accordance with BS EN 10204
3.1, the 2004 edition, or its ISO version 10474 3.1, the 2013 edition. This standard defines the types of inspection documents for metallic products.

The standard outlines different types of certificates, each representing varying levels of inspection and documentation. Common types include Type 2.1, Type 2.2,
Type 3.1, and Type 3.2. It’s crucial to verify that the certificate type matches the required level of inspection for your specific application.

Here, 3.1 indicates the type of inspection document. Other types include 2.1, 2.2, and 3.2.

Certificate type 2.1 is a Declaration of Compliance with the order, while 3.2 is a Test Report issued by both the manufacturer’s authorized inspection
representative, independent of the manufacturing department, and an independent inspector.

I’ll explain this in more detail in the upcoming video.

For this video, 3.1 means these pipes have been inspected by the manufacturer’s inspection department, which operates independently of the production
department. The material meets all the quality requirements specified in the purchase order.

So, this field will provide you with the level of inspection conducted on the material.

Step 2- The Administrative Information

I have highlighted this section, which contains information such as the customer’s name, order number, and the manufacturer’s internal work order. These details
will help you correlate this TC with your purchase order.

Step 3 – The Manufacturing Process

This field is the first technical detail you need to check. Material manufacturers can use different methods of manufacturing, and ASME and ASTM material
specifications specify the acceptable methods for specific material grades.
For example, seamless pipes can be manufactured using methods such as hot rolled, cold rolled, or forging. In this sample MTR our seamless pipes are
manufactured using the hot-rolled method.

So, check this and confirm with your material grade. If you are checking pipe fittings, they can be wrought or forged, and the same goes for other products.

Step 4 – The Product Type

The pipe can be seamless, ERW, spiral wound, or LSAW welded pipe. The type of pipe offered for inspection is mentioned here. In our sample TC, it is a seamless
pipe.

For pipe fittings, it can be an elbow, tee, reducer, or other types depending on the order.

Step 5 – The Surface Condition of the Product

Steel products such as pipes and fittings can be supplied with external surfaces painted, galvanized, or bare. Most manufacturers will supply these products with
just a rust-preventive varnish coating, as is the case here.

The final painting will be done on-site. Typically, there is no internal painting required for carbon steel materials used in process piping. However, galvanized pipes
are also used for some utility services.

The surface condition of the product depends on the requirements of the purchase order. So, you can confirm this with the order requirements.

Step 6 – The Standards and Specifications of the Material.

The Mill Test Report should indicate the relevant standards that the product complies with, such as API, ASME, ASTM, NACE, and others. This ensures that the
material meets the required product specifications and quality standards, and that the product has been produced and tested according to recognized industry
standards.

In our sample TC, the pipes meet multiple standards such as API 5L PSL2, ASTM A53 and A106, ASME SA53 and SA106. I am not aware of AFP. If you know it,
mention it in the comments.

These pipes also meet NACE MR0175 and MR0103 requirements. NACE standards certify that the product can withstand corrosive environments.

Step 7 – The End Type of the Product

The end type of the product, either plain ends or beveled ends, is specified here. Depending on the welding requirements, you can specify the end types. Usually,
small bore and less thick pipes come with plain ends, while for higher thickness, J-type or V-type ends can be used.

Before we move on to the next part of the video, if you want to advance your career in the oil and gas industry and gain practical knowledge from industry
experts, you can check out our comprehensive online courses on my website, hardhatengineer.com. Click the link in the description to enroll today and accelerate
your learning journey.

Step 8 – The Dimension Information of the Seamless Pipe

The MTR should include key material dimensions such as length, diameter, thickness, or any other relevant measurements. Verifying these dimensions ensures
that the material accurately matches your project requirements.

Here, the first detail mentioned is the size of the pipe, which can be stated in millimeters (as in this case) or inches. The second detail is related to the schedule
number of the pipe, specifying the thickness. However, it is marked as “not applicable” here. Can you guess why?

That’s because the thickness of the pipe is mentioned along with the pipe size. The next field mentions the length of the pipe. “D R” means double random.

During production, pipes are not manufactured in the same lengths, and during the construction of process plants, varying lengths of pipes are required. To
address this issue, standards have defined pipe lengths in single random and double random categories.

Single random pipes are shorter in length and typically range from 4.8 to 6.7 meters. However, in a given lot, 5% of the pipes can have lengths between 3.7 and
4.8 meters. Pipes shorter than this specified range are not acceptable.

On the other hand, double random pipes are longer in length. The entire lot must have a minimum average length of 10.7 meters, and the shortest pipe cannot
be shorter than 4.8 meters. Additionally, within the lot, 5% of the pipes can have lengths ranging from 4.8 meters to 10.7 meters.

The next field indicates the quantity of pipes offered for inspection in the current lot. Finally, the last field in the dimension block represents the nominal weight
of the pipe, measured in kilograms per meter.

Review of Material test certificates is a long and time taking task at the beginning. But once you get the experience, it will be much easier and faster.

Review Mechanical Testing Result

Step 9 – Verify the Mechanical Test Results.

The material certificate should provide details of the key mechanical tests conducted on the material, such as tensile strength, yield strength, and elongation.
Reviewing these results ensures that the material meets the required mechanical properties for its intended application.

Let’s go through the details provided in each column. The first column is the heat number of the material. The heat number is a unique identification number
assigned to each batch or lot of material during manufacturing.

By referencing the material heat number, manufacturers, suppliers, and customers can access detailed records or certificates that provide information about the
material’s composition, properties, and production history.

After the heat number, a sample number is given. It is used to track the sample in the lab. The next column, “zone,” indicates the location from which the sample
was taken (end one or end two). Refer to the explanation provided for each shortcode used in the table to understand these references.

The following column shows the lot number of the pipe. One heat number can have multiple lot numbers, indicating that the pipes with these lot numbers were
manufactured in the same batch.

The “specimen condition” column indicates the location and condition of the sample. In this case, “LS” refers to the location of the sample, where “B” indicates
that the sample is taken from the pipe body. “SC” denotes the specimen condition, and “AM” means “As Manufactured,” indicating that no additional treatment
has been given to the sample, and it is directly cut from the pipe.

For mechanical testing, the sample can be a rounded bar or a flat metal strip. Here, it is mentioned that the sample type is a strip cut from the pipe body.

The last column in this section indicates the orientation from which the sample was cut from the pipe. “L” indicates the longitudinal direction. You can see the
location of the sample in the pipe shown here.

Let’s move on to the next column, which displays the dimensions of the sample, including length, width, and area. Once the sample is cut from the pipe, it is
machined to the dimensions specified by the testing standard before conducting destructive testing.

The following column indicates the testing temperature. “RT” means room temperature. Please note that depending on the material’s service conditions, the
testing temperature can be sub-zero or higher than room temperature.

The remaining columns show the results of the mechanical tests. “YS” refers to yield strength, with the minimum and maximum acceptable values for the
material grade and the obtained result mentioned in the first column. Following yield strength, “UTS” indicates ultimate tensile strength, with the same format of
minimum and maximum values alongside the obtained result. The unit for both yield strength and ultimate tensile strength is megapascals (MPa).

The last three columns display the results of the elongation test, including the initial length of the sample in millimeters, the minimum acceptable percentage,
and the obtained result.

It is crucial to cross-check the minimum and maximum values of all these test results with the applicable material standards. In this case, the standards are A106,
API 5L, and A53.
Chemical Test Result Review in Material Test Certificates

Step 10 – Verifying the Chemical Test Results

In this table, the first four columns are related to the identification of the sample, as discussed earlier.

The Material Test Report should outline the chemical analysis of the material, specifying the minimum and maximum acceptable levels of each alloying element.
In the blue box, you can see the minimum and maximum values provided for the material grade.

“H” indicates the value given in the heat number, while “P” represents the result obtained in the product testing. The table displays various alloying elements and
their percentages. You may be wondering why these percentages add up to more than 100%. Well, if you look at the top row, you’ll see the “x time
multiplication” mentioned.

For example, the value of carbon is 18 divided by 100, which equals 0.18. Similarly, the value of phosphorus is 15 divided by 1000, and so on.

“CE” represents the carbon equivalent of the steel. There are different formulas to calculate CE, and the formula used here is provided in the note below. “PCM”
is used to measure crack susceptibility, and you can refer to the formula given to calculate the crack susceptibility factor, which involves more alloying elements
than the carbon equivalent.

“F1,” “F2,” “F3,” and “F4” are other factors used to measure the remaining alloying elements, and the formulas for each of these factors are also provided.

To determine acceptable values, refer to the material standards.

Review Hardness Test Details in MTR

Step 11 – Verifying the Hardness Test Results

After checking the mechanical and chemical test results, you need to examine the surface hardness of the pipe. In this case, the HBW 2.5 with a 187.5 scale is
used, which means a Brinell 2.5 mm tungsten carbide ball is used with a 187.5-kilogram force load for testing.

The maximum acceptable value is 237 BHN (Brinell Hardness Number), and the result obtained is 146 BHN.
Bend Test, Hydro Test, and Heat Treatment Records Check in MTC

Step 12 – Check the Bend Test Result

Bend tests are conducted to assess the material’s ductility and resistance to cracking. The result is determined through visual examination. If any cracks are
observed in the bend area, the sample will not be accepted.

Step 13 – Confirm the Hydro Test Result.

The unit of pressure testing is PSI (pounds per square inch), and the test pressure is 2,970 PSI. The holding time is only 5 seconds, and the result is acceptable.
The pressure requirements are calculated based on the pipe’s thickness, and the holding time value is specified in the applicable pipe standards.

Step 14 – Heat Treatment Details

Here, the pipes are normalized at 880 degrees Celsius for a holding time of 37 minutes. The heat treatment requirements depend on the material standards, pipe
thickness, and manufacturing methods.

Special and Supplementary Requirements in Material Certificate

Step 15 – Special Requirements

If any special requirements are specified in the purchase order, as in this case, they are checked in Step 15. Here, two special requirements are mentioned: one
related to residual magnetism and the other related to end protection using a plastic cap.

Step 16 – Supplementary Requirements

Next, certain supplementary requirements need to be checked according to the standard and good practice. Let’s see some of them in Step 16.

Here, the steel manufacturing method, mercury contamination, and gas removal methods are mentioned. Additionally, pipe rolling, visual and dimensional
inspection status, and welding repair status are mentioned.

The last piece of information is the edition of the standards used to certify the pipe, which is also stated. It’s important to check the material using the current
edition of the standards mentioned in the Material Test Certificate, as requirements may change with different editions.

Non-Destructive Testing

Step 17 – The Non-Destructive Testing (NDT)

In the image given above, you can see the list of NDT carried out during the manufacturing of the pipe. For the pipe body, Electro-Magnetic Inspection (EMI) has
been conducted to check for cracks or pitting defects. In addition to EMI, Magnetic Particle Testing is also performed on the pipe ends to identify defects in the
beveled face of the pipe.

The next detail mentioned is the temperature of the pipe during the entire manufacturing process before it is allowed to cool in still air.

Marking Requirements Checks

Step 18 – Check the Marking Details on the Product.

Here, you can see that manufacturing standards such as API, ASTM, ASME, material grade, pipe size, thickness (schedule number), length, heat number, etc., are
marked on the pipe using the stencilling method.

By following this step-by-step method, you can review the Material Test Certificate of any product.
What is Order of Precedence in Technical Document of Construction Contracts?

When there are conflicting acceptance criteria and you are in dispute with the other party, how to resolve this kind of dispute?

In this blog post, you will learn about the Order of Precedence in Technical Documents of Construction Contracts and how it can be used
to resolve disputes arising from conflicting acceptance criteria. Additionally, we will explore the importance of the Order of Precedence in
commercial contracts.

Table of Contents

• Importance of Order of Precedence

• Resolving Conflicting Acceptance Criteria
• The Order of Precedence List
• How to Use the Order of Precedence?: A Four-Step Process
• Importance of Order of Precedence in Commercial Contracts
• Conclusion
Importance of Order of Precedence

The Order of Precedence is a legal way to resolve ambiguity in commercial contracts. It is a critical clause in any kind of commercial
agreement, including technical documents. By establishing a hierarchy of criteria or requirements, the Order of Precedence helps manage
conflicts, ensure smooth contract administration, and foster better relationships between contracting parties.

Resolving Conflicting Acceptance Criteria

Let’s say you are doing dimension checking of this pipe spool. During the inspection, you found that the straightness of the flange face is not
acceptable. It is tilted more than required.

But, at the same time, the Contractor is showing you the other document, and as per that, it is acceptable. How will you decide in this
situation?

See the image for more clarification. Acceptable limits mentioned in Documents A and B are shown, and the actual reading.

Document A, which is Project Specification, has a one millimeter acceptance limit. However, as per Document B, which is Piping Standards,
the acceptance limit is 1.5 millimeters.

Document A Project Specification Document B Piping Standard

1 mm 1.5 mm

Actual – 1.5 mm

This is just an example not Real Criteria

Here comes the order of the preceding in the picture. It is a legal way to resolve the ambiguity in commercial contracts.
The Order of Precedence List
In the event of ambiguity or conflict among the documents within the contract, the order of precedence will follow in descending order.
Here is the sample list. What does it mean? The first document in the order has the highest precedence and the precedence gets reduced
when you move lower in the list.
You have to follow the order of the document to identify the acceptance criteria.

• Signed Contract
• Statutory Requirements
• Scope of Work
• Project Specification – Document – A in our case.
• Project Procedures
• Design Code and Standard – Document – B in our case.
So, in this example, the design code and standard have the lowest precedence, and the signed contract has the highest precedence.

In our example, document – A (Project Specification) is above Document – B (Design Code and Standard) in the list, which means the
requirements mentioned in Document – A shall follow.

This is how conflicts are resolved when there are different acceptance criteria for the same things.

So, when faced with conflicting acceptance criteria, simply refer to the Order of Precedence to figure out which set of criteria has higher
precedence and you should be followed that. It’s like having a compass that guides you toward clarity and consistency in decision-making.
How to Use the Order of Precedence? A Four-Step Process

Step 1: Identify conflicting acceptance criteria.

Recognize that there are conflicting criteria or requirements from different sources or documents. This could include contractual
agreements, technical specifications, industry standards, or any other relevant sources that govern the inspection process.

Step 2: Refer to the designated Order of Precedence.

Consult the applicable technical documents or contracts that establish the Order of Precedence. These documents should outline the
specific hierarchy or ranking of criteria or requirements to be followed in case of conflicts.

Step 3: Determine the highest priority document or criteria.

Review the Order of Precedence and identify the highest-ranking document or criteria. This will be the reference point for resolving the
conflict and making a decision.

Step 4: Follow the specified order to resolve the conflict.

Evaluate the conflicting acceptance criteria based on the established Order of Precedence. Compare the criteria or requirements in
question and determine which takes precedence according to the designated hierarchy.

Importance of Order of Precedence in Commercial Contracts

Not only in Technical Documents but it is a critical clause in any kind of commercial contract.
Because it helps manage and resolve conflicts that may arise due to ambiguity in the construction contracts.

It provides structure, clarity, risk management, efficient operation, and control over the requirements. It also plays a vital role in resolving
conflicts, ensuring smooth contract administration, and fostering better relationships between contracting parties where there are
conflicting or inconsistent terms in a contract.

Conclusion

In conclusion, the Order of Precedence is a crucial aspect of technical documents and commercial contracts. It serves as a compass,
guiding stakeholders toward clarity and consistency in decision-making. By understanding and correctly applying the Order of Precedence,
you can effectively resolve disputes and ensure smooth contract execution.
What is Sour Service in Process Piping?

What is Sour Service?

Any process fluid that contains hydrogen sulphide is defined as Sour Service. As per MR0175, it is a process atmosphere that contains H2S,
which may lead to cracking in the material.

Sour Service is also known as wet H2S service in a refinery. You must be thinking, what is special about it?

Well! H2S is a highly toxic gas present in the Oil and Gas environment. A small exposure to it may have a serious effect on human health. It is
colorless and flammable. It has a very unpleasant smell.

If it leaks into the atmosphere and when combined with water, it can create acid rain.

In refineries, it is found in crude oil areas, hydro treater areas, LPG areas, and wastewater facilities.

It is heavier than air, so it will sit in the lower area and wait for its prey.

Not only this, its presence leads to corrosion in metals such as Sulphide stress cracking, Hydrogen induced cracking, stepwise cracking,
and Stress-oriented hydrogen induced cracking.

This type of material cracking leads to catastrophic equipment failure in plants.

So, this H2S is dangerous for humans, the environment, and property. That is why special attention is required when it comes to sour
service.

What Materials are Used in Sour Services?

Regular Carbon steel, Alloy steel, and stainless steel are used in sour service. Here, I have listed a few for your reference.

But there are a few additional requirements that these material needs to meet before installing.

Here are the additional requirements for carbon and low alloy steel.

1. Steel shall be manufactured by Basic Oxygen Process or Electric arc furnace.

2. Steel to be Killed & fine grained.

3. Materials shall be in Normalized Condition.

4. Nickel % limited to < 1%

5. Carbon content< 0 .23%

6. Carbon Equivalent < 0.43%

7. Hardness < 22 HRC

8. Sulphur content< 0.01%

Similarly, for stainless steel material, there are specific requirements of alloying elements and heat treatment with limited max hardness.

Now let’s see What are additional tests required for these materials.

What are the Additional Tests Required for Sour Service Materials?

1. HIC – Hydrogen Induced Cracking

2. SSC – Sulphide stress cracking,

3. SOHIC – Stress oriented hydrogen induced cracking

Also, after welding, PWHT is required for all carbon and low alloy steel material used in sour service.

Requirements for testing and acceptance criteria are given in NACE MR0175. So, go through it if you want to know in more detail.

Also, note that NACE MR0175 is the same as ISO 15156.

This is the end of the video. Please visit my website hardhatengineer.com to learn more about piping and piping material. And don’t forget to
subscribe. See you soon with the next video. Goodbye, take care.